Output tray having an increased capacity for stapled

ABSTRACT

An inclined output tray has a cutout depression in its right rear corner to receive the portion of each group of stapled sheets having the staple. The cutout depression increases the capacity of the inclined output tray since it compensates for the staples increasing the overall thickness of the stack.

RELATED APPLICATIONS

[0001] U.S. patent application, Ser. No. 09/774,852, filed Jan. 31,2001, of Michael Kurt Gordon et al for “Finisher With Sheet PlacementControl.” U.S. patent application Ser. No. 09/793,360, filed Jan. 31,2001, of Jeffery Allen Ardery et al for “Finisher With Frictional SheetMover.” U.S. patent application of Jeffery Allen Ardery et al for “SheetBeam Breaker,” Ser. No. (unassigned), filed on even date herewith. U.S.patent application of Daniel Mlejnek et la for “Finisher With SingleRoller For Frictionally Moving Each Sheet,” Ser. No. (unassigned), filedon even date herewith.

FIELD OF THE INVENTION

[0002] This invention relates to an output tray for receiving stapledgroups of sheets for stacking and, more particularly, to a output trayhaving a corner area of its sheet support surface formed with a cutoutdepression to compensate for the thickness of the staples relative tothe thickness of the stapled sheets in stacking groups of stapledsheets.

BACKGROUND OF THE INVENTION

[0003] In the aforesaid application of Jeffery Allen Ardery et al, for“Finisher With Single Roller For Frictionally Moving Each Sheet,” asupport surface of an inclined output tray receives each stapled groupof sheets. When two sheets, for example, are stapled to each other toform a group of stapled sheets, more staples will exist in a stack ofstapled sheets of groups of two stapled sheets than for any greaternumber of stapled sheets in a group for the same total number of sheets.For example, fifty staples would be present in a stack of 100 sheetswhen each group has only two sheets stapled to each other while onlytwenty staples would be present for 100 stacked sheets when each groupof the stapled sheets has five sheets stapled to each other. Because astaple is substantially thicker than a sheet of paper and the staplesare substantially aligned with each other when stacked on the inclinedoutput tray, the stack of sheets in the right rear (as viewed from thefront) corner of the inclined output tray is significantly higher wheneach group of the stapled sheets is in a range of two to five sheetsthan when each group of the stacked sheets is greater than five.

[0004] This is because there is a decrease in the number of sheets thatcan be fed to the inclined output tray before the height of the stack ofstapled sheets blocks the fed sheets when there is no compensation forthe thickness of the staple in comparison with the thickness of a sheetof paper. As a result, this increased height of the stacked sheets inthe right rear corner prevents stapled sheets from being fed to theinclined output tray earlier than if there were no staples in thesheets. Thus, the capacity of the inclined output tray is significantlyreduced as the number of staples in the stacked sheets increases.

SUMMARY OF THE INVENTION

[0005] The inclined output tray of the present invention has itscapacity significantly increased in comparison with the prior inclinedoutput tray when each stapled group contains two sheets, for example.The inclined output tray of the present invention solves this capacityproblem by providing a recess or depression in a corner area in whichthe staples are substantially vertically aligned with each other wheneach group of the stapled sheets is stacked on top of the other groups.

[0006] Comparison tests have shown an increase of 50% in the capacity ofthe inclined output tray of the present invention in comparison with thesame inclined output tray having no compensation for the relativelylarge thickness of the staple in comparison with the thickness of asheet of paper. With five stapled sheets in each group, the comparisontest disclosed that the capacity of the inclined output tray of thepresent invention increased 54.2% relative to the inclined output trayhaving no compensation for the relatively large thickness of the staplesin comparison with the thickness of the sheet of paper.

[0007] As the number of the sheets in each group of stapled sheetsincrease to ten, there is less increase in the overall height of thestacked stapled sheets in the right rear corner of the inclined outputtray. This results in less capacity increase of the inclined output trayof the present invention in comparison with the same inclined outputtray without compensation for the staples although there is still anincrease until there are more than twenty sheets in each stapled group.At twenty-five sheets in each stapled group, there is no increase incapacity as the tests were conducted in groups of five sheets stapled toeach other after the two sheet group.

[0008] Of course, most groups of stapled sheets are usually in the rangeof 2-5 sheets. Thus, there is a significant increase in capacity of theinclined output tray of the present invention for this range incomparison with the same inclined output tray without the cutoutdepression in the right rear corner.

[0009] An object of this invention is to provide an output tray havingan increased capacity of stapled sheets.

[0010] Another object of this invention is to provide an inclined outputtray having an increased capacity of stapled sheets.

[0011] Other objects of this invention will be readily perceived fromthe following description, claims, and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The attached drawings illustrate a preferred embodiment of theinvention, in which:

[0013]FIG. 1 is a front perspective view of a printer having a finisherdisposed thereon.

[0014]FIG. 2 is a right side perspective view of the finisher of FIG. 1including an aligning roller, an accumulator table receiving sheetsfalling by gravity for support thereby during advancement by thealigning roller towards two substantially perpendicular referencebarriers, and an inclined output tray to which each sheet (shown inphantom) is advanced after being aligned with the two reference barriersby the aligning roller.

[0015]FIG. 3 is a left side perspective view of the finisher of FIG. 2with left and right bails added thereto.

[0016]FIG. 4 is a schematic top plan view showing a sheet partiallysupported on the accumulator table after being fed thereto from exitcorrugation rollers in solid lines and a dash line position to which thesheet is initially moved by the aligning roller.

[0017]FIG. 5 is a schematic top plan view, similar to FIG. 4, showingadvancement of the sheet from the final position of FIG. 4 (solid linesin FIG. 5) and engagement of a rear edge of the sheet with a rearreference barrier in dash lines.

[0018]FIG. 6 is a schematic top plan view, similar to FIGS. 4 and 5, inwhich the solid line position is the position to which the sheet wasadvanced in FIG. 5 and the dash line position is at completion ofadvancement of the sheet with a side edge engaging a side referencebarrier.

[0019]FIG. 7 is a perspective view of a sheet aligning assembly of thefinisher.

[0020]FIG. 8 is an exploded perspective view of the sheet aligningassembly of FIG. 7.

[0021]FIG. 9 is an exploded perspective view of a sub-assembly of thesheet aligning assembly of FIG. 8 including a pivotally mounted housingand the aligning roller supported by the pivotally mounted housing.

[0022]FIG. 10 is a rear perspective view of a portion of the finisher ofFIG. 7 showing the sheet aligning assembly of FIG. 7 disposed relativeto the accumulator table of the finisher.

[0023]FIG. 11 is a fragmentary top plan view of the sheet aligningassembly of FIG. 7 along with a printed sheet in its initial position indash lines and in its aligned position after completion of sheetadvancement by the aligning roller in solid lines.

[0024]FIG. 12 is a fragmentary side elevation view of the aligningroller in its home or rest position in which the aligning roller doesnot rotate, a portion of the accumulator table on which each printedsheet is supported, and a driving crank.

[0025]FIG. 13 is a fragmentary side elevation view, similar to FIG. 12,of the aligning roller in its frictional contact position with a printedsheet for advancing the printed sheet to its aligned position, theportion of the accumulator table, and the driving crank advanced 180°from its home position of FIG. 12.

[0026]FIG. 14 is a fragmentary side elevation view, similar to FIG. 13,of the aligning roller, the portion of the accumulator table with thealigning roller removed from its sheet contact position in FIG. 13, andthe driving crank advanced 90° from its position in FIG. 13 but 90°prior to its position in FIG. 12.

[0027]FIG. 15 is a perspective view of a sub-assembly of the aligningroller and its support.

[0028]FIG. 16 is a front perspective view of a gear box of the finisherincluding a gear train for driving various portions of the finisherduring each cycle of operation.

[0029]FIG. 17 is a perspective view of a clamp arm having a lowerportion for receiving each sheet as it is advanced by the aligningroller towards the side reference barrier and a cam follower arm havinga clamp for clamping each printed sheet after it is advanced against theside reference barrier.

[0030]FIG. 18 is a bottom plan view of the clamp arm and the camfollower arm of FIG. 17.

[0031]FIG. 19 is a front perspective view of the finisher and showing anelectric stapler for stapling aligned stacked sheets.

[0032]FIG. 20 is a top plan view of a portion of the accumulator tableand showing the location of the electric stapler relative to eachprinted sheet at the aligned position.

[0033]FIG. 21 is a perspective view of the bail actuator used in thefinisher of the present invention.

[0034]FIG. 22 is a side schematic view of a bail actuator in its rest orhome position with a sheet beginning to exit from two sets of exitcorrugation rollers.

[0035]FIG. 23 is a side schematic view, similar to FIG. 22, with thebail actuator pivoted 20° from its position of FIG. 22.

[0036]FIG. 24 is a side schematic view, similar to FIGS. 22 and 23, withthe bail actuator at its maximum pivoted position prior to the sheetfalling by gravity as it leaves the exit corrugation rollers.

[0037]FIG. 25 is a perspective view showing the relation between theleft bail and the bail actuator when the bail actuator has pivoted toits position of FIG. 23.

[0038]FIG. 26 is a right side perspective view that is the same as FIG.2 except that a printed sheet is shown with a longitudinal downwardlyfacing arch extending the length of the sheet.

[0039]FIG. 27 is a side schematic view that is the same as FIG. 22except that a printed sheet has a longitudinal downwardly facing archextending the length of the sheet.

[0040]FIG. 28 is a perspective view of an inclined output tray having asingle group of stapled sheets supported thereby with a recess ordepression in the right rear corner of the inclined output tray forreceiving the corner of the single group of stapled sheets having thestaple.

[0041]FIG. 29 is a perspective view of the inclined output tray of FIG.28 with a plurality of groups of stapled sheets supported thereby.

[0042]FIG. 30 is a perspective view of the inclined output tray of FIGS.28 and 29 with the inclined output tray full of groups of stapled sheetssupported thereby.

[0043]FIG. 31 is a graph comparing the capacity of the inclined outputtray of FIG. 28 with its right rear corner having a recess or depressionfor receiving the stapled corners and the capacity of an inclined outputtray with no recess or depression in its right rear corner withdifferent numbers of sheets for each job or group.

[0044]FIG. 32 is a side elevational view of the accumulator table andthe inclined output tray with a printed sheet disposed thereon with itsupwardly facing arch extending laterally.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0045] Referring to the drawings and particularly FIG. 1, there is showna printer 10 having a finisher 11, which can be detachable from theprinter 10 and is supported thereby. One suitable example of the printer10 is a laser printer sold under the trademark OPTRA by the assignee ofthis application or as modified in the future.

[0046] When the finisher 11 is releasably attached to the printer 10,printed sheets 12 (see FIG. 2) are fed in sequence from the rear of theprinter 10 (see FIG. 1) vertically into the rear of the finisher 11.This may be in a known manner such as described in U.S. Pat. No.5,810,353 to Baskette et al, for example.

[0047] The finisher 11 includes an accumulator table 14 (see FIG. 2)having an upper support surface 15 to which each of the printed sheets12 is fed by an upper cooperating set 16 (see FIG. 3) of four exitcorrugation rollers 16A mounted on a shaft 16B and a lower cooperatingset 17 of two large corrugation rollers 17A and three small corrugationrollers 17B mounted on a shaft 17C (see FIG. 2). The axial spacing ofthe four exit corrugation rollers 16A (see FIG. 3) on the shaft 16Brelative to the two large corrugation rollers 17A and the three smallcorrugation rollers 17B of the set 17 is particularly shown anddescribed in the aforesaid Ardery et al application, Ser. No.09/793,360, which is incorporated by reference herein.

[0048] Thus, the corrugation rollers 16A and the corrugation rollers 17Aand 17B cooperate to induce wave shapes across each of the printedsheets 12 (see FIG. 2) exiting therefrom but only while the printedsheets 12 are engaged by the rollers 16A, 17A, and 17B. After each ofthe printed sheets 12 exits the two sets 16 and 17 of the exitcorrugation rollers 16A, 17A, and 17B, each of the printed sheets 12falls onto the upper support surface 15 of the accumulator table 14 forsupport thereby or on top of another of the printed sheets 12 alreadysupported by the upper support surface 15 of the accumulator table 14.The printed sheet 12 falls by gravity and the engaging force of a pivotactuator 19 (see FIG. 21) also falling by gravity.

[0049] As each of the printed sheets 12 (see FIG. 2) falls onto theupper support surface 15 of the accumulator table 14, most of each ofthe printed sheets 12 will be supported on an inclined output tray 18.The inclined output tray 18 is spring mounted to be continuously urgedupwardly to maintain the vertical separation between the upper supportsurface 15 of the accumulator table 14 and the topmost sheet 12supported on the inclined output tray 18 as the printed sheets 12 aredisposed on it.

[0050] The bail actuator 19 (see FIG. 21) has a pair of arcuateextensions 19A and 19B pivotally mounted on the shaft 16B (see FIG. 22)of the upper set 16 of the exit corrugation rollers 16A. As each of theprinted sheets 12 exits from between the corrugation roller sets 16 and17, its leading edge 19C engages a back surface 19D of each of thearcuate extensions 19A and 19B (see FIG. 21) in a portion not wrappedaround the shaft 16B. This exerts a force on the bail actuator 19 tocause the bail actuator 19 to move from its rest or home position ofFIG. 22 to its position in FIG. 23 through the bail actuator 19 pivoting20° about the axis of the shaft 16B.

[0051] When the bail actuator 19 is in the position of FIG. 23, a camsurface 19E (see FIG. 21) at the bottom of a leg 19F of the bailactuator 19 causes pivotal movement of a left bail 20 (see FIG. 25)through the cam surface 19E engaging a cam surface (not shown) on thebottom surface of a bottom portion 20A of an actuation arm 20B of theleft bail 20. The left bail 20 is pivotally mounted through two pivotpins 20C being supported in a mounting bracket 20D (see FIG. 3), whichis attached to a top cover (not shown) supported on a side frame 20F(one shown in FIG. 1) of the finisher 11. This is more particularlyshown and described in the aforesaid Gordon et al application, Ser. No.09/779,852, which is incorporated by reference herein.

[0052] A right bail 21 (see FIG. 3) is similarly pivotally mounted bytwo pivot pins 21A being supported in a mounting bracket 21B, which alsois attached to the top cover (not shown) supported on the side frame(one shown at 20F in FIG. 1) of the finisher 11. The right bail 21 has acam surface (not shown) on the bottom surface of a bottom portion 21C(see FIG. 3) of an actuating arm 21D engaged by a cam surface 22 (seeFIG. 21) at the bottom of a leg 23 of the bail actuator 19 for movementat the same time as the left bail 20 (see FIG. 3). Therefore, the bails20 and 21 cooperate to support the printed sheet 12 (see FIG. 24) in themanner more particularly shown and described in the aforesaid Gordon etal application, Ser. No. 09/779,852.

[0053] The leading edge 19C (see FIG. 23) of the printed sheet 12advances from the position of FIG. 23 until the bail actuator 19 reachesits maximum pivoted position of FIG. 24. The leading edge 19C (see FIG.22) of the printed sheet 12 rode along the back surface 19D of each ofthe arcuate extensions 19A (see FIG. 21) and 19B until it reached a mainportion 25 of the bail actuator 19. Thereafter, the leading edge 19C(see FIG. 23) of the printed sheet 12 rode along a back surface 26 of asheet engaging member 27, which extends downwardly from the main portion25 (see FIG. 21) of the bail actuator 19.

[0054] After reaching the position of FIG. 24 and rear edge 37 (see FIG.4) of each of the printed sheets 12 exits the corrugation rollers 16A(see FIG. 2), 17A and 17B, the bail actuator 19 (see FIG. 24) begins tofall by gravity to cause pivoting of the bail actuator 19 about the axisof the shaft 16B so that the printed sheet 12 is removed from support bythe bails 20 (see FIG. 3) and 21. This results in the bails 20 and 21also pivoting downwardly by gravity due to the bail actuator 19 (seeFIG. 21) pivoting downwardly by gravity.

[0055] The sheet engaging member 27 (see FIG. 24) of the bail actuator19 pushes downwardly on the printed sheet 12. This causes the printedsheet 12 to fall by gravity to the upper support surface 15 of theaccumulator table 14 and the inclined output tray 18 (see FIG. 2).

[0056] As the bail actuator 19 (see FIG. 24) falls downwardly bygravity, a wire bail 28 engages the printed sheet 12. As shown in FIG.21, the wire bail 28 includes a horizontal front portion 28A having acurved horizontal portion 28B at each end connected to an angledhorizontal portion 28C. Each of the angled horizontal portions 28C isconnected by a curved horizontal portion 28D to a rear horizontalportion 28E. Each of the rear horizontal portions 28E terminates in avertical end portion 28F extending upwardly therefrom.

[0057] Each of the vertical end portions 28F is disposed in a retainer29 mounted on each of the legs 19F and 23 of the bail actuator 19. Thisprevents horizontal movement of the wire bail 28.

[0058] The rear horizontal portion 28E has a snap fit in a groove 30 inan extension 31 of each of the legs 19F and 23 of the bail actuator 19to prevent downward movement of the wire bail 28. The rear horizontalportion 28E also has a snap fit in a groove 32 in a retainer 33 on theextension 31 of each of the legs 19F and 23 of the bail actuator 19 toprevent upward movement of the wire bail 28.

[0059] The horizontal front portion 28A of the wire bail 28 preferablyhas a length of about five inches. It is desired that the horizontalfront portion 28A of the wire bail 28 extend as wide as possible.

[0060] The horizontal front portion 28A of the wire bail 28 breaks anylongitudinal beam created in the printed sheet 12 (see FIG. 24) becauseof a curl created in the printed sheet 12 by a fuser (not shown) of theprinter 10 (see FIG. 1), for example. This occurs after the printedsheet 12 (see FIG. 24) falls by gravity and is supported on the uppersupport surface 15 of the accumulator table 14.

[0061] This is because the fuser (not shown) of the printer 10 creates alongitudinally extending curl in the printed sheet 12 to form the beamor arch along the entire length of the printed sheet 12 with adownwardly facing arch. The horizontal front portion 28A (see FIG. 21)of the wire bail 28 breaks the longitudinal beam, if it exists, in theprinted sheet 12 (see FIG. 24) after it is supported on the uppersupport surface 15 of the accumulator table 14. The horizontal frontportion 28A (see FIG. 21) of the wire bail 28 creates a beam in thedirection of the width of the printed sheet 12 (see FIG. 24) with adesired upwardly facing arch configuration. This upwardly facing arch ofthe printed sheet 12 increases the beam strength of each of the printedsheets 12 in the direction of alignment in which each of the printedsheets 12 is moved.

[0062] The downwardly facing arch in the printed sheet 12 is shown inFIG. 26 at 34 and is larger than shown. It also is shown in FIG. 27.FIG. 26 also shows the printed sheet 12 not falling by gravity in thedesired shape because of the longitudinal beam in the printed sheet 12.

[0063] When each of the printed sheets 12 (see FIG. 2) falls by gravityonto the upper support surface 15 of the accumulator table 14, analigning roller 35 must be maintained in an elevated position, which isits home position of FIG. 12, to enable the printed sheet 12 (see FIG.2) to fall by gravity onto the accumulator table 14. The aligning roller35 is shown in FIG. 2 in its frictional contact position with theprinted sheet 12 to be advanced by the aligning roller 35.

[0064] The accumulator table 14 includes a rear wall 36, which issubstantially perpendicular to the upper support surface 15. The rearwall 36 functions as a rear reference barrier for engagement by the rearedge 37 (see FIG. 4) of each of the printed sheets 12.

[0065] The rear edge 37 of the printed sheet 12 must be within 10 mm. ofthe rear wall 36 (see FIG. 2) of the accumulator table 14. There ispreferably only 4 mm. between the rear edge 37 (see FIG. 4) of theprinted sheet 12 and the rear wall 36 of the accumulator table 14 (seeFIG. 2). If the spacing is greater than 10 mm., the aligning roller 35cannot advance the printed sheet 12 in the manner shown in FIGS. 4-6.

[0066] The aligning roller 35 is supported by a sheet aligning assembly38 (see FIG. 7) for movement from its home position, which is shown inFIG. 12, to its frictional contact position, which is shown in FIG. 13,for engagement with each of the printed sheets 12 (see FIG. 4) and thenreturned to its home position. The sheet aligning assembly 38 (see FIG.10) includes a frame 39, which is supported by walls 40 (see FIG. 16)and 40′ of a gear box 41.

[0067] As shown in FIG. 7, the frame 39 has a main shaft 42 rotatablysupported in its end walls 43 and 44. The frame 39 has an intermediatewall 45 between the end walls 43 and 44.

[0068] A housing 46 is mounted on the main shaft 42 for pivotal movementin both directions about the axis of the main shaft 42. The pivotallymounted housing 46 includes a cylindrical portion 47 (see FIG. 9) havinga circular passage 48 extending therethrough.

[0069] A roller shaft 49 is rotatably supported in the circular passage48 of the cylindrical portion 47 of the pivotally mounted housing 46.The roller shaft 49 has the aligning roller 35 retained on its enlargedend 50 by a resilient finger 51 disposed in a slot 52 in a hub 52′ ofthe aligning roller 35 and engaging the hub 52′. This connection causesrotation of the aligning roller 35 only when the roller shaft 49 isrotated.

[0070] The roller shaft 49 has its other end 53 extending beyond thecylindrical portion 47 of the housing 46 to support a helical gear 55.The helical gear 55 is held on the roller shaft 49 (see FIG. 11) by aC-clip 56 disposed in a groove 57 (see FIG. 9) in the roller shaft 49.

[0071] The roller shaft 49 has flat side portions 58 and 59 againstwhich flat side portions 60 and 61, respectively, of a circular passage62 extending through the helical gear 55 engage. Accordingly, when thehelical gear 55 is rotated, the roller shaft 49 rotates to rotate thealigning roller 35. Each side of the helical gear 55 has a boss 64 (oneshown in FIG. 9) extending slightly beyond the remainder of each side ofthe helical gear 55.

[0072] The helical gear 55 meshes with a helical gear 65 (see FIG. 7).The helical gear 65 is mounted on the main shaft 42 to be driventhereby. The helical gear 65 rotates with the main shaft 42 through flatside portions (one shown at 66 in FIGS. 7 and 8) on the main shaft 42engaging cooperating flat side portions (not shown) of a circularpassage 67 (see FIG. 8) in the helical gear 65. Each side of the helicalgear 65 has a boss 68 (one shown in FIG. 8) extending slightly beyondthe remainder of the helical gear 65.

[0073] A C-clip 69 is disposed in a groove 70 in the main shaft 42 toposition the helical gear 65 on the main shaft 42 through limiting itsaxial movement to the left in FIG. 7. This insures that the teeth of thehelical gear 65 and the teeth of the helical gear 55 will always mesh.

[0074] The pivotally mounted housing 46 (see FIG. 9) has a circularpassage 71 to receive the main shaft 42 (see FIG. 7). This mounts thehousing 46 on the main shaft 42 so that it may pivot in either directionon the main shaft 42.

[0075] The pivotally mounted housing 46 is disposed next to the helicalgear 65 but slightly spaced therefrom because of the boss 68 (see FIG.8) on the helical gear 65 engaging the adjacent side of the pivotallymounted housing 46 (see FIG. 7). A C-clip 72 (see FIG. 8) is disposed ina groove 72′ in the main shaft 42 to hold the pivotally mounted housing46 (see FIG. 7) on the main shaft 42 by limiting its axial movement tothe right. Thus, the housing 46 is pivotally mounted on the main shaft42 so that it can pivot relative to the main shaft 42 in either aclockwise or counterclockwise direction as the main shaft 42 is rotatedin only one direction.

[0076] A C-clip 73 (see FIG. 8) is disposed in a groove 74 in the mainshaft 42. The C-clip 73 engages the left (as viewed in FIG. 7) side ofthe intermediate wall 45 of the frame 39 to prevent movement of the mainshaft 42 to the right.

[0077] The main shaft 42 is driven by a gear 76 (see FIGS. 10, 11, and16) having its teeth mesh with teeth on a gear 77 (see FIG. 16) of agear train in the gear box 41 of the finisher 11 (see FIG. 1). When anelectromagnet 78 (see FIG. 16) of a clutch 79 is energized, a DC motor80 causes rotation of the gear 76. This drives the main shaft 42 at apredetermined velocity during each cycle of operation.

[0078] A hollow projecting guide 81 (see FIG. 8) on the end wall 44 ofthe frame 39 is disposed within a corresponding shaped opening (notshown) in the wall 40 (see FIG. 16) of the gear box 41. This alignmentinsures that the gears 76 and 77 mesh satisfactorily.

[0079] The gear 76 (see FIG. 10) is mounted on a flattened end 82 (seeFIG. 7) of a drive shaft 83 extending through the hollow projectingguide 81 on the exterior of the end wall 44 of the frame 39. The driveshaft 83 extends through the opening (not shown) in the wall 40 (seeFIG. 16) of the gear box 41 to insure that the gear 76 is disposedwithin the gear box 41.

[0080] As shown in FIG. 7, the drive shaft 83 extends through a passagein the hollow projecting guide 81. The drive shaft 83 is rotatablysupported in each of the end wall 44 and the intermediate wall 45 of theframe 39.

[0081] A drive gear 86 (see FIG. 8) is attached to the drive shaft 83.The drive gear 86 meshes with an idler gear 87.

[0082] The idler gear 87 is rotatably supported on a stub shaft 88,which extends through an opening 89 in the end wall 44 of the frame 39to receive the idler gear 87. The idler gear 87 meshes with a smallergear 90 of a compound gear 91.

[0083] The compound gear 91 is rotatably mounted on the main shaft 42.The compound gear 91 has its larger gear 92 mesh with a smaller gear 93of a compound gear 94, which is rotatably mounted on the drive shaft 83.

[0084] The compound gear 94 has its larger gear 95 mesh with a drivegear 96, which is attached to the main shaft 42 for causing rotationthereof. Flat side portions 97 (one shown in FIG. 8) of the main shaft42 cooperate with flat side portions (not shown) in a circular passage98 in the drive gear 96.

[0085] The drive shaft 83 (see FIG. 8) has a crank 100 attached theretothrough the drive shaft 83 being disposed in a hole 101 in the crank100. The hole 101 is smaller at its end remote from the intermediatewall 45 of the housing 39 so that an end 102 of the drive shaft 83engages this reduced portion of the hole 101 to have fixed engagementtherewith.

[0086] The direct connection of the crank 100 to the drive shaft 83results in the crank 100 rotating at a much slower velocity than themain shaft 42. The main shaft 42 makes approximately 3.75 revolutionsper cycle of operation of the drive shaft 83, and the connected crank100 rotates only one revolution per cycle of operation since the driveshaft 83 makes only one revolution per cycle of operation.

[0087] The crank 100 has a pin 105 formed integral therewith andextending through a longitudinal slot 106 in a link 107. A C-clip 108 isdisposed in a groove 109 in the pin 105 of the crank 100 to maintain thepin 105 in sliding relation with the link slot 106. The link 107 has acircular passage 110 extending therethrough to receive a connecting pin111 (see FIG. 9) extending through the circular passage 110 (see FIG. 8)into a circular passage 112 (see FIG. 9) in the housing 46 with whichthe connecting pin 111 has a press fit.

[0088] Rotation of the crank 100 (see FIG. 8) by the drive shaft 83imparts pivotal motion to the housing 46 (see FIG. 7) during each cycleof operation. A spring 115 extends between a spring anchor 116 on thehousing 46 and a portion (not shown) of the gear box 41 (see FIG. 16).This results in the spring 115 (see FIG. 7) continuously exerting aforce on the pivotally mounted housing 46 so that a force iscontinuously exerted on the aligning roller 35 when it is in contactwith the sheet 12 (see FIG. 11).

[0089] Thus, the spring 115 (see FIG. 7) continuously urges thepivotally mounted housing 46 away from the home position, as shown inFIG. 12, of the aligning roller 35 supported thereby. As a result, theforce of the spring 115 (see FIG. 7) continuously causes the aligningroller 35 to exert a maximum normal force of a predetermined amount suchas 50-60 grams, for example, on each of the printed sheets 12 (see FIG.4) when the aligning roller 35 (see FIG. 7) comes in frictional contacttherewith. This frictional contact position of the aligning roller 35 isshown in FIG. 13.

[0090] While the spring 115 (see FIG. 7) is the preferred force exertingmeans on the aligning roller 35, it should be understood that othersuitable force exerting means such as a counterweight, for example maybe employed, if desired. While the crank 100 (see FIG. 8) is preferred,it should be understood that a cam and a cam follower may be employedfor controlling pivotal movement of the housing 46, if desired.

[0091] The housing 46 (see FIG. 9) also supports a deflector 120 fordeflecting each of the printed sheets 12 (see FIG. 2) as each of theprinted sheets 12 is aligned on the support surface 15 (see FIG. 2) ofthe accumulator table 14. This prevents each of the printed sheets 12(see FIG. 11) from buckling upwardly when its side edge 123 engages anadjacent side reference barrier 122.

[0092] Additionally, a tongue 121 (see FIG. 9), which is preferably apolyester film sold under the trademark MYLAR, is adhered to the bottomof the deflector 120 by a suitable adhesive. The tongue 121, whichpreferably has a thickness of 0.004″, rides on each of the printedsheets 12 (see FIG. 2) to prevent the printed sheet 12 from riding upthe rear wall 36 of the accumulator table 14 during alignment.

[0093] The deflector 120 (see FIG. 9) has a slot 120A to receive aprojection 120B on the housing 46 to prevent rotation of the deflector120. A flange 120C on the deflector 120 engages the end of the housing46 to limit movement of the deflector 120 onto the housing 46. A flange120D on the connecting pin 111 engages the flange 120C on the deflector120 when the connecting pin 111 has a press fit in the connecting pin111.

[0094] The teeth of each of the helical gear 55 (see FIG. 7) and thehelical gear 65 preferably have the same angle. However, there may be aslight difference between the angles of the teeth of the helical gear 55and the helical gear 65, if desired.

[0095] The sum of the angles of the teeth of the helical gear 55 and thehelical gear 65 is equal to the angle of the aligning roller 35 relativeto the side reference barrier 122 (see FIG. 11). The spacing between theside reference barrier 122 and the adjacent side edge 123 of the printedsheet 12 is typically 25 mm. and a maximum of 33 mm. for 8½×11 paper andtypically 33 mm. and a maximum of 39 mm. for A4 paper.

[0096] With each of the helical gear 55 (see FIG. 7) and the helicalgear 65 having their teeth at an angle of 33°, the sum of the angles is66°. This also is the angle of the aligning roller 35 to the sidereference barrier 122 (see FIG. 11) so that the angle of the aligningroller 35 (see FIG. 2) to the rear wall 36 of the accumulator table 14is 24°.

[0097] While the angle of 66° is preferred, it should be understood thatan angle in the range of 60° and 70° between the aligning roller 35 (seeFIG. 11) and the side reference barrier 122 is satisfactory and otherangles also could be employed, if desired. Furthermore, it should beunderstood that any angle greater than 45° of the aligning roller 35with respect to the side reference barrier 122 will cause a greaterforce to be exerted on each of the printed sheets 12 to move it moretowards the side reference barrier 122 than towards the rear wall 36.

[0098] As shown in FIG. 4, the aligning roller 35 initially rotates theprinted sheet 12 clockwise from the solid line position until its corner124 engages the rear wall 36 as shown in dash lines in FIG. 4 and insolid lines in FIG. 5. The clockwise rotation is indicated by an arrow125.

[0099] The aligning roller 35 next advances the printed sheet 12 fromthe solid line position of FIG. 5 to the dash line position. Thisincludes both counterclockwise rotation (as indicated by an arrow 126)and sliding motion of the printed sheet 12. At this time, the rear edge37 of the printed sheet 12 has its entire surface engaging the rear wall36.

[0100] Then, the aligning roller 35 advances the printed sheet 12 fromthe solid line position of FIG. 6, which is the same as the dash lineposition of FIG. 5, until the side edge 123 of the printed sheet 12engages the side reference barrier 122 as shown in dash lines in FIG. 6.At this time, the aligning roller 35 is removed from frictional contactwith the printed sheet 12 by the pivotal motion of the housing 46 (seeFIG. 7). During motion of the printed sheet 12 (see FIG. 6) only towardsthe side reference barrier 122, the rear edge 37 of the printed sheet 12slides along the rear wall 36 with which it is in engagement so as to bein alignment therewith.

[0101] In FIG. 6, the side edge 123 of the printed sheet 12 is inengagement with the side reference barrier 122 so as to be in alignmenttherewith. As used in the claims, the term “alignment” of the rear edge37 with the rear wall 36 or the side edge 123 of the printed sheet 12with the side reference barrier 122 means that they are in engagement.

[0102] As the side edge 123 of the printed sheet 12 approaches the sidereference barrier 122, it engages an angled side surface 127 (see FIG.17) of a lower portion 128 of a pivotally mounted clamp arm 129. Theclamp arm 129 is pivotally mounted on a pin 130 (see FIG. 16), which isfixed to a plate 141. A lever 131 also is pivotally mounted on the plate141 of the gear box 41.

[0103] As shown in FIG. 18, the clamp arm 129 has a support 132extending from one side thereof and on which a counterweight 133 isretained by a snap fit. The force exerted by the counterweight 133 onthe clamp arm 129 continuously urges the lower portion 128 (see FIG. 17)downwardly with a predetermined force. When the side edge 123 (see FIG.11) of the printed sheet 12 approaches the side reference barrier 122,it engages the angled side surface 127 (see FIG. 17) of the lowerportion 128 of the pivotally mounted clamp arm 129 before it reaches theside reference barrier 122 (see FIG. 11). The location of the lowerportion 128 is shown in phantom in FIG. 11 relative to the rear wall 36and the side reference barrier 122.

[0104] The counterweight 133 (see FIG. 18) provides a force of aboutseven grams. This force is sufficient to resist curl forces in each ofthe printed sheets 12 (see FIG. 11) as it moves under the lower portion128 (see FIG. 17) of the pivotally mounted clamp arm 129.

[0105] While the counterweight 133 (see FIG. 18) is the preferredexerting force, it should be understood that the exerting force could beprovided by other suitable means such as a spring 134 (shown in phantomin FIG. 17) extending between a spring anchor 135 on the clamp arm 129and a spring retaining portion (not shown) on the lever 131.

[0106] As the side edge 123 (see FIG. 11) of the printed sheet 12engages the side reference barrier 122, a clamp 136 (see FIG. 17 andshown in phantom in FIG. 11) on an end of a cam follower arm 137 ismoved into engagement with the printed sheet 12 (see FIG. 11) topositively clamp the printed sheet 12 against the support surface 15(see FIG. 17) of the accumulator table 14. The cam follower arm 137 alsois pivotally mounted on the pivot pin 130 (see FIG. 16).

[0107] The pivotal movement of the cam follower arm 137 (see FIG. 17) iscontrolled by a cam 138 to remove the clamp 136 during alignment of eachof the printed sheets 12 (see FIG. 11). A gear 139 (see FIG. 17) isintegral with the cam 138. A stud 140 (see FIG. 16) rotatably supportsthe cam 138 and the gear 139. The stud 140 is supported on the plate 141of the gear box 41.

[0108] The gear 139 is driven by the motor 80 through the gear train.The gear train includes a pair of bevel gears 142 and 143 to change theaxis of rotation of the gear 139 90° from the axes of rotation of thegears of the portion of the gear train driving the gear 76. Thus, onerevolution of the cam 138 occurs during each cycle of operation when thegear 76 is driven one revolution.

[0109] The cam follower arm 137 is continuously urged against the cam138 by a spring 144 (see FIG. 17). The spring 144 is attached to thelever 131 and to an extension 146 of the cam follower arm 137.

[0110] As shown in FIG. 18, the extension 146 of the cam follower arm137 extends through a slot 147 in the clamp arm 129. The spring 144 (seeFIG. 17) maintains the cam follower arm 137 in contact with the cam 138.This insures that the clamp 136, which extends through a hole 148 (seeFIG. 18) in the clamp arm 129, contacts the printed sheet 12 (see FIG.11) only after the side edge 123 of the printed sheet 12 has engaged theside reference barrier 122. This clamping arrangement insures that theprinted sheets 12 remain in their aligned relationship to which theyhave been moved.

[0111] The clamp 136 (see FIG. 17) remains in its sheet engagingposition until the edge 123 (see FIG. 6) of the next of the sheets 12approaches the reference barrier 122. When this occurs, the cam 138 (seeFIG. 17) lifts the cam follower arm 137 to lift the clamp 136 so thatthe edge 123 (see FIG. 6) can move against the reference barrier 122.After the edge 123 of the sheet 12 has engaged the reference barrier122, the cam 138 (see FIG. 17) drops the cam follower arm 137 to returnthe clamp 136 into contact with the printed sheet 12 (see FIG. 6) toclamp it and all of the sheets therebeneath.

[0112] This cycle continues until the number of the printed sheets 12 tobe stapled together is accumulated. Then, an electric stapler 150 (seeFIG. 19) is energized.

[0113] The stapler 150 has a throat 151 through which a staple 152 (seeFIG. 28) is pushed upwardly to staple the number of sheets selected inaccordance with a microprocessor (not shown) in the finisher 11 (seeFIG. 1). The printed sheets 12 (see FIG. 28) face downwardly so it isnecessary for the staples 152 to be pushed upwardly through the throat151 (see FIG. 19) to staple the aligned printed sheets 12 (see FIG. 11)to each other to form each group of the stapled printed sheets 12. Itshould be understood that the staple 152 (see FIG. 19) is in the upperleft corner of each of the stapled sheets 12.

[0114] One suitable example of the electric stapler 150 (see FIG. 19) issold by Max Co., Ltd., Tokyo, Japan as Model No. EH-320. Any othersuitable electric stapler may be employed, if desired.

[0115] After each group of the printed sheets 12 (see FIG. 20) has beenstapled together by the stapler 150, the lower portion 128 (see FIG. 17)of the pivotally mounted clamp arm 129 and the clamp 136 on the camfollower arm 137 must be moved out of the path of the printed sheets 12(see FIG. 11). This allows each group of the printed sheets 12 to beremoved from any support by the upper support surface 15 (see FIG. 2) ofthe accumulator table 14 and advanced to the rearwardly inclined outputtray 18 for complete support thereby. This occurs before the start ofthe next cycle of operation.

[0116] A spring 153 (see FIG. 17), which is attached to a hook 153A onthe plate 141 and a hook 153B on the lever 131, continuously biases thelever 131 towards the clamp arm 129. A rod 155 (see FIG. 16) has itsright end contacting a longitudinal arcuate surface (not shown) of thepivotally mounted lever 131. When the rod 155 is in the position of FIG.16, the rod 155 overcomes the force of the spring 153 to prevent thespring 153 from causing the lever 131 to pivot clockwise about the pivotpin 130.

[0117] The lever 131 has a lifter 156 (see FIG. 17) connected theretofor engaging the clamp arm 129 and the cam follower arm 137 to causeeach to pivot clockwise about the pivot pin 130 (see FIG. 16) when therod 155 drops off an interior cam surface (not shown) of a cam 154. Thisclockwise pivoting of the clamp arm 129 and the cam follower arm 137results in the lower portion 128 (see FIG. 17) of the pivotally mountedclamp arm 129 and the clamp 136 on the cam follower arm 137 being raisedupwardly away from and out of the path of the printed sheets 12 (seeFIG. 11).

[0118] The rod 155 (see FIG. 16) is moved to the left by the gear trainin the gear box 41 rotating a gear 155′, which is integral with the cam154, to change the portion of the interior cam surface of the cam 154engaging the rod 155 when the lever 131 is to pivot clockwise from theposition of FIG. 17 to move the pivotally mounted clamp arm 129 and theclamp 136 on the cam follower arm 137 upwardly out of the path of theprinted sheets 12 (see FIG. 11).

[0119] When the lower portion 128 (see FIG. 17) of the clamp arm 129 andthe clamp 136 on the cam follower arm 137 are to be reset so as to againengage the next printed sheet 12 (see FIG. 11) as it is aligned, thegear train in the gear box 41 (see FIG. 16) further rotates the gear155′ to change the portion of the interior cam surface (not shown) ofthe cam 154 engaging the rod 155. This returns the rod 155 to theposition in FIG. 16 in which it contacts the pivotally mounted lever 131to hold it against the force of the spring 153.

[0120] The gear train in the gear box 41 also drives endless belts orbands 157 having pusher tabs 158 thereon. The pusher tabs 158 areutilized to push each group of the stapled printed sheets 12 (see FIG.28) to the inclined output tray 18 after stapling and before the nextcycle of operation. The belts or bands 157 ride in grooves 159 (see FIG.17) in the support surface 15 of the accumulator table 14 and in thefront portion of the accumulator table 14.

[0121] It should be understood that the belts or bands 157 (see FIG. 16)and the pivotally mounted lever 131 are only activated after a staplingoperation is completed to move each group of the stapled printed sheets12 (see FIG. 28) to the inclined output tray 18. If stapling is notoccurring and each of the printed sheets 12 is not advanced foralignment, then the belts or bands 157 (see FIG. 16) and the pivotallymounted lever 131 are activated after each of the sheets 12 (see FIG. 2)is ejected onto the accumulator table 14. This activation of the beltsor bands 157 (see FIG. 16) and the pivotally mounted lever 131 iscontrolled by the microprocessor (not shown) in the finisher 11 (seeFIG. 1).

[0122] The inclined output tray 18 (see FIG. 2) has its sheet supportsurface 165 formed with a cutout recess or depression 166 in its rightrear (as viewed from the front) corner. A wall 167 (see FIG. 1) of thefinisher 11 constitutes a wall of the recess or depression 166 (see FIG.2) of the inclined output tray 18.

[0123] Accordingly, after the stapled printed sheets 12 are stapled bythe electric stapler 150 (see FIG. 20), each group of the stapledprinted sheets 12 is advanced along the sheet support surface 165 (seeFIG. 2) of the inclined output tray 18. This advancement positions thestapled portion of each group of the stapled printed sheets 12 with itsstaple 152 (see FIG. 28) disposed above the recess or depression 166 sothat the portion of the printed sheet 12 having the staple falls thereinuntil the recess or depression 166 is filled as shown in FIG. 30.

[0124] As the number of the groups of the stapled printed sheets 12increases as shown in FIGS. 29 and 30, a larger number of the groups ofthe stapled printed sheets 12 can be disposed on the sheet supportsurface 165 of the inclined output tray 18 than in the prior inclinedoutput tray, which did not have the recess or depression 166. The recessor depression 166 prevents the staples 152 from increasing the overallheight of the right rear corner of the groups of the stapled printedsheets 12 as quickly to limit the capacity of the inclined output tray18.

[0125] Thus, as shown in FIG. 30, it takes a relatively large number ofthe groups of the stapled sheets 12 before the stack in the right rearcorner rises higher than the left rear corner. That is, the right rearcorner becomes higher than the left rear corner only when the relativelylarge number of the groups of the stapled printed sheets 12 are stackedas shown in FIG. 30; this is when the inclined output tray 18 is full asindicated by a sensor (not shown).

[0126] It should be understood that the number of the stapled printedsheets 12 in each group of the stapled printed sheets 12 has asignificant effect on how quickly the stapled corners of the stapledprinted sheets 12 rise above the recess or depression 166. For example,when there are only two of the printed sheets 12 stapled to each other,the right rear corner of the stack of the printed sheets 12 risesquicker than if each of the groups of the printed sheets 12 had a largernumber of the printed sheets 12 stapled to each other. This is becausethe thickness of the staple 152 is the determining factor in the overallthickness of each stapled group since the thickness of the staple 152 ismuch greater than the thickness of each of the printed sheets 12. Withonly two of the printed sheets 12 stapled together, a greater number ofthe staples 152 is present for the same total number of the printedsheets 12.

[0127] The relation of the capacity of the inclined output tray 18having the recess or depression 166 and the capacity of the inclinedoutput tray 18 without the recess or depression 166 is shown by graphlines 169 and 170, respectively, in FIG. 31. This was based on thefollowing results from comparison tests: Tray 18 Capacity Sheets/Jobwith recess 160 Tray 18 without recess 160 increase (%) 2 126 84 50.0 5370 240 54.2 10 580 510 13.7 15 660 615 7.3 20 720 700 2.9 25 750 7500.0.

[0128] While the cutout recess or depression 166 (see FIG. 29) has beenshown and described as being formed along two adjacent edges at theright rear corner of the support surface 165 of the inclined output tray18, it should be understood that the recess or depression 166 could beformed along only one edge of the sheet surface 165, if the staple 152were located at a different position in each of the stapled sheets 12.

[0129] While the roller shaft 49 (see FIG. 9) has been shown anddescribed as driven by the helical gears 55 and 65 (see FIG. 7), itshould be understood that other gears may be employed. For example,bevel gears may be utilized.

[0130] An advantage of this invention is that it allows a greater numberof stapled sheets to be stacked on an inclined output tray of a finisherthan previously available. Another advantage of this invention is thatthe height of the stacked sheets does not reach a level to block feedingas early as in the prior inclined output tray.

[0131] For purposes of exemplification, a preferred embodiment of theinvention have been shown and described according to the best presentunderstanding thereof. However, it will be apparent that changes andmodifications in the arrangement and construction of the parts thereofmay be resorted to without departing from the spirit and scope of theinvention.

What is claimed is:
 1. An output tray having a support surface forreceiving groups of stapled sheets from a source; and said supportsurface having a recess extending along at least a portion of one of itsedges in which each group of stapled sheets has at least one staple foreach group of stapled sheets disposed at a location to be received insaid recess when each group of stapled sheets is received by saidsupport surface.
 2. The output tray according to claim 1 in which saidsupport surface has a recess extending along a portion of each twoadjacent edges defining a corner in which each group of stapled sheetshas its only staple disposed.
 3. The output tray according to claim 2 inwhich the source of the stapled sheets is a finisher.
 4. The output trayaccording to claim 1 in which the source of the stapled sheets is afinisher.
 5. An inclined output tray having a support surface forreceiving groups of stapled sheets from a source; and said supportsurface having a recess extending along at least a portion of one of itsedges in which each group of stapled sheets has at least one staple foreach group of stapled sheets disposed at a location to be received insaid recess when each group of stapled sheets is received by saidsupport surface.
 6. The inclined output tray according to claim 5 inwhich said support surface has a recess extending along a portion ofeach two adjacent edges defining a corner in which each group of stapledsheets has its only staple disposed.
 7. The inclined output trayaccording to claim 6 in which the source of the stapled sheets is afinisher.
 8. The inclined output tray according to claim 5 in which thesource of the stapled sheets is a finisher.